Component mounting machine, feeder device, and splicing work defect determination method

ABSTRACT

A component mounting machine includes: a feeder device; a component transfer device; a splice portion detecting section detecting a splice portion further on a near side than a supply position of the feeder device; a passing determination section determining if the splice portion is in the passing state in which the splice portion is positioned within a passing area; a suction abnormality determination section determining the suction abnormality state in which a suction nozzle is not able to suck a component; a work defect determination section determining the splicing work defect when the suction abnormality state is determined and the splice portion is determined to be in the passing state; and an abnormality display section that performs dedicated abnormality display when the splicing work defect is determined.

TECHNICAL FIELD

The present invention relates to a component mounting machine and afeeder device, and in further detail, relates to determination of adefect in splicing work for connecting two carrier tapes that are usedin the feeder device.

BACKGROUND ART

A solder printing machine, a component mounting machine, a reflowmachine, a hoard inspection machine, and the like may be used asequipment for producing a hoard on which multiple components aremounted. Typically, a board production line is configured by connectingthese sets of equipment to each other. Among these, the componentmounting machine is provided with a board conveyance device, a componentsupply device, a component transfer device, and a control device. Thereis a feeder device for the method for feeding out the carrier tape onwhich cavity sections that hold components lined up in one row as arepresentative example of the component supply device. When a firstcarrier tape that is used by the feeder device approaches a tail end, anoperator performs splicing work for connecting a second carrier tapeusing splice tape. A technical example which relates to this type offeeder device is disclosed in PTL 1 and PTL 2.

The component supply feeder of PTL 1 has means for electricallyconnecting with an external device, means for storing information thatis obtained by the electrical connection, and means for displaying thestored information. Mounting positional information of the componentsupply feeder that is mounted to the component mounting apparatus orinformation about a supplied electronic component is indicated asinformation that is stored and displayed. Thereby, concerning variouserrors such as a recognition error in which there is no component on thesupply position or a suction error in which the component is not suckedby a suction nozzle, it is possible to explicitly recognize errorcontent.

In addition, an electronic component mounting device of PTL 2 isprovided with means for detecting a mistake in taking out a component bya takeout tool (suction nozzle), means tor detecting a characteristicpart of a storage tape (carrier tape), and means for determining passageof a connecting tape (splice tape) that connects old and new storagetapes based on the detection result of the characteristic part. Thereby,it is possible to conveniently detect a join part that is connected bythe connecting tape. Giving supplemental explanation, ordinarily,several cavity sections that are positioned in front and at the rear ofthe splice tape do not hold an electronic component, and a componenttakeout mistake is inevitably generated in the cavity section. Then, inthe technique of PTL 2, it is determined that the connecting tape haspassed, while detecting the component takeout mistake. Thereby, noabnormality is determined even if the component takeout mistake isgenerated, and a skip operation of the storage tape is also possible.

CITATION LIST Patent Literature

PTL 1: JP-A-2004-47572

PTL 2: JP-A-2014-123636

SUMMARY OF INVENTION Technical Problem

Note that, typically multiple feeder devices are equipped in a componentcounting machine in order to mount many types of components on a board,and multiple feeder devices are further used in a component mountingline that consists of multiple component mounting machines. Therefore,the operator needs to frequently perform splicing work, and is requiredto accurately perform splicing work in a short time. When splicing workis not accurate, as a result of splice tape peeling or getting caught, atape feeding defect is generated, and production of a board isinterrupted due to the generation of a suction mistake.

The suction mistake is generated for various reasons in another splicingwork defect. Even if a state after production is interrupted by thesuction mistake is investigated, in many cases the splice tape isalready discharged, and it is not easy to specify a cause. If it isassumed that it is possible to specify that the cause of the suctionmistake is a splicing work defect, investigation and implementation ofrecurrence prevention measures, technological improvement of operators,or the like are efficiently performed, and productivity is finallyimproved. However, the technologies of PTL 1 and PTL 2 do not determinea splicing work defect.

The present invention is made in consideration of the problems of thebackground art, and a problem to be solved is to provide a componentmounting machine that is able to determine whether or not the cause ofoccurrence of a suction abnormality state in which a component is notable to be sucked is the cause of the splicing work defect, a feederdevice, and a splicing work defect determination method.

Solution to Problem

The present invention to solve the problems described above provides acomponent mounting machine including: a feeder device that feeds out acarrier tape that is formed with cavity sections, that hold components,lined up in a row and sequentially supplies the components to apredetermined supply position; a component transfer device that has asuction nozzle that sucks the component from the cavity section of thesupply position and mounts the component on a board, a mounting headthat holds the suction nozzle, and head driving mechanisms that drivethe suction nozzle and the mounting head; a splice portion detectingsection that is provided at a detection position further on a near sidethan the supply position of the feeder device and detects the spliceportion that connects a tail end of a first carrier tape and a leadingend of a second carrier tape with each other; a passing determinationsection that determines whether or not the splice portion is in apassing state in which, when a position at which the splice portion isfed out from the detection position by a predetermined length longerthan a separation distance between the detection position and the supplyposition is referred to as a discharge position, the splice portion ispositioned within a passing area from the detection position to thedischarge position; a suction abnormality determination section thatdetermines a suction abnormality state in which the suction nozzle isnot able to suck the component from the cavity section of the supplyposition; a work defect determination section that determines a splicingwork defect in a case where the suction abnormality state is determinedand the splice portion is determined to be in the passing state; and anabnormality display section that performs dedicated abnormality displayin a case where the splicing work defect is determined.

There is provided a feeder device of the present invention that isequipped in a component mounting machine, feeds out a carrier tape thatis formed with cavity sections, that hold components lined up in onerow, and sequentially supplies the components to a predetermined supplyposition, the device provided with: a splice portion detecting sectionthat is provided at a detection position further on a near side than thesupply position and detects the splice portion that connects a tail endof a first carrier tape and a leading end of a second carrier tape witheach other; a passing determination section that determines whether ornot the splice portion is in a passing state in which a position atwhich, when the splice portion is fed out from the detection position bya predetermined length longer than a separation distance between thedetection position and the supply position is referred to as a dischargeposition, the splice portion is positioned within a passing area fromthe detection position to the discharge position; a work defectdetermination section that determines a splicing work defect in a casewhere a suction abnormality state is determined in which the component;mounting machine is not able to suck the component from the cavitysection at the supply position and the splice portion is determined tobe in the passing state; and an abnormality display section thatperforms dedicated abnormality display in a case where the splicing workdefect is determined.

The present invention provides a splicing work defect determinationmethod that is a method for determining a defect of splicing work inwhich a tail end of a first carrier tape and a leading end of a secondcarrier tape are connected with each other, in a component mountingmachine provided with a feeder device that feeds out a carrier tape thatis formed with cavity sections that hold components lined up in one rowand sequentially supplies the components to a predetermined supplyposition, and a component transfer device that has a suction nozzle thatsucks the component from the cavity section of the supply position andmounts the component on a board, a mounting head that holds the suctionnozzle, and head driving mechanisms that drive the suction nozzle andthe mounting head, the method comprising: a splice portion detectionstep of detecting the splice portion at a detection position further ona near side than the supply position of the feeder device; a passingdetermination step of determining whether or not the splice portion isin a passing state in which, when a position at which the splice portionis fed out from the detection position by a predetermined length longerthan a separation distance between the detection position and the supplyposition is referred to as a discharge position, the splice portion ispositioned within a passing area from the detection position to thedischarge position; a suction abnormality determination step ofdetermining a suction abnormality state in which a suction nozzle is notable to suck the component from the cavity section of the supplyposition; a work defect determination step of determining a splicingwork defect in a case where the suction abnormality state is determinedand the splice portion is determined to be in the passing state; and anabnormality display step of performing dedicated abnormality display ina case where the splicing work defect is determined.

Advantageous Effects of Invention

In a component mounting machine of the present invention, a splicingwork defect is determined and dedicated abnormality display is performedin a case where a suction abnormality state is determined in which it isnot possible for the suction nozzle to suck a component and a spliceportion is determined to be in a passing state. Accordingly, when thesuction abnormality state occurs, an operator is able to determinewhether or not the cause of the suction abnormality state is caused bythe splicing work defect by confirming whether or not an abnormalitydisplay section performs dedicated abnormality display.

In addition, since the feeder device of the present invention isprovided with substantially the same configuration requirements as thecomponent mounting machine of the present invention described above, thesame effects as the component mounting machine of the present inventionoccur.

Furthermore, since the splicing work defect determination method of thepresent invention is a method for replacing a function of configurationrequirements of the component mounting machine of the present inventionin respective implementation steps, the same effects as the componentmounting machine of the present invention occur.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a planar view illustrating an entire configuration of acomponent mounting machine of an embodiment.

FIG. 2 is a side view of a feeder device of a first embodiment that isequipped in the component mounting machine of the embodiment.

FIG. 3 is a block diagram illustrating a configuration for control ofthe feeder device of the first embodiment.

FIG. 4 is a top view of a splice portion that connects two carriertapes.

FIG. 5 is a side view of the splice portion.

FIG. 6 is a top view of an operation panel of the feeder device.

FIG. 7 is a diagram of a process flow that explains operation of thecomponent mounting machine of the embodiment.

FIG. 8 is a table that indicates display content of an abnormalitydisplay section of the operation panel.

FIG. 9 is a diagram of a process flow of a control section that explainsoperation of a feeder device of a second embodiment.

FIG. 10 is a table that indicates display content of an abnormalitydisplay section in the second embodiment.

DESCRIPTION OF EMBODIMENTS

(1. Entire Configuration of Component Mounting Machine 1 of theEmbodiments)

An entire configuration of a component mounting machine 1 of anembodiment of the present invention will be described with reference toFIG. 1. FIG. 1 is a planar view illustrating an entire configuration ofa component mounting machine 1 of an embodiment. A direction from apaper surface left side toward the right side in FIG. 1 is an X-axisdirection along which a board K is carried in and out, and a directionfrom the front on the paper surface lower side toward the rear of thepaper surface upper side is a Y-axis direction. The component mountingmachine 1 is configured by assembling a board conveyance device 2,multiple feeder devices 3, a component transfer device 4, a componentcamera 5, a control device 6, and the like on a device table 9. Theboard conveyance device 2, each feeder devices 3, the component transferdevice 4, and the component camera 5 are controlled by the controldevice 6, and respectively carry out predetermined work.

The board conveyance device 2 carries in the board K to a mountingexecution position, and positions and carries out the board K. The boardconveyance device 2 consists of a pair of guide rails 21, 22, a pair ofconveyor belts, a backup device, and the like. The multiple feederdevices 3 supply each of the components sequentially. The multiplefeeder devices 3 are equipped lined up on a pallet table 91 on the upperface of the device table 3. Each feeder device 3 holds a tape reel 7 onthe front side of a main body section 31 and sets the supply position 32on the upper portion near the rear side of the main body section 31. Thefeeder device 3 is equivalent to the feeder device of the firstembodiment of the present invention, and the detailed descriptionthereof will be described later.

The component transfer device 4 sucks and collects components from eachcomponent supply position 32 of the multiple feeder devices 3, and thecomponents are conveyed up to the positioned board K and mounted. Thecomponent transfer device 4 is a device of an XY-robot type that ishorizontally movable in the X-axis direction and the Y-axis direction.The component transfer device 4 is constituted by a pair of Y-axis rails41 and 42 and a Y-axis slider 43 that constitute a head drivingmechanism, a mounting head 44 that is driven in the X-axis direction andthe Y-axis direction, a nozzle tool 45, a suction nozzle 46, a boardcamera 47, and the like. The nozzle tool 45 has a suction nozzle 46 thatsticks the component and is mounted on the board K while beingreplaceably held in the mounting head 44. The board camera 47 isprovided in the mounting head 44 and images a positional fiducial markthat is attached to the board K and accurately detects the position ofthe board K.

The component camera 5 is provided with an upward orientation on anupper face of the device table 9 between the board conveyance device 2and the feeder device 3. The component camera 5 images the state of thecomponents that are sucked by the suction nozzle 46 while the mountinghead 44 is moved from the feeder device 3 on the board K. The controldevice 6 is assembled on the device table 9 and the installationposition of the control device 6 is not particularly limited. Thecontrol device 6 controls the component mounting operation according toa mounting sequence that is held advance.

(2. Detailed Configuration of Feeder Device 3 of First Embodiment)

Next, the detailed configuration of the feeder device 3 will bedescribed. FIG. 2 is a side view of a feeder device 3 of a firstembodiment that is equipped in the component mounting machine 1 of theembodiment. In addition, FIG. 3 is a block diagram illustrating aconfiguration for control of the feeder device 3 of the firstembodiment. The feeder device 3 is configured by the main body section31, a splice tape detection sensor 33, a feeding sprocket 34, adischarge roller 36, an operation panel 38, a control section 39, andthe like.

A reel supporting section 311 that is provided near to the lower portionon the front side of the main body section 31 rotatably and attachablyand detachably supports the tape reel 7. The tape reel 7 winds and holdsa carrier tape 71. A tape guide member 312 that guides the carrier tape71 that is pulled out from the tape reel 7 is disposed approximatelyhorizontally near the upper portion of the main body section 31. Thesplice tape detection sensor 33 is provided near the front side of thetape guide member 312. The supply position 32 is set near the rear sideof the tape guide member 312.

FIG. 4 is a top view of a splice portion 79 that connects two carriertapes 71 (71A, 71B). In addition, FIG. 5 is a side view of the spliceportion 79. Each carrier tape 71 consists of a bottom tape 72 and acover tape 73. The bottom tape 72 is made of paper or resin and cavitysections 74 that hold a component P are formed lined up in one row.Furthermore, sprocket holes 75 are formed lined up in one row along oneside edge of the bottom tape 72. The cover tape 73 is made of a thinfilm, and is bonded to the bottom tape 72 by two adhesive portions. Thecover tape 73 covers the cavity sections 74 to prevent drop out of thecomponent P, and does not cover the sprocket holes 75.

When the component P of the first carrier tape 71A that is used thefeeder device 3 becomes small, an operator performs splicing work forconnecting the second carrier tape 71B that holds components P of thesame type. First, the operator trims a tail end 71E of the first carriertape 71A and the leading end 71T of the second carrier tape 71B andcauses the tail end 71E and the leading end 71T to abut with each other.Next, the operator bonds a bottom side splice tape 76 so as to straddlethe bottom tape 72 of both carrier tapes 71A and 71B. In the samemanner, the operator bonds a cover side splice tape 77 so as to straddlethe cover tape 73 of both carrier tapes 71A and 71B. The bottom sidesplice tape 76 and the cover side splice tape 77 do not cover thesprocket holes 75.

A predetermined number of cavity sections 74 counted from the tail end71E of the first carrier tape 71A do not hold the components P. In thesame manner, a predetermined number of cavity sections 74 counted fromthe leading end 71T of the second carrier tape 71B do not hold thecomponents P. In FIGS. 4 and 5, a case in indicated of a case where thepredetermined number of tail ends 71E and leading ends 71T is three. Notlimited thereto, the predetermined number is modifiable, or thepredetermined number of tail ends 71E and leading ends 71T may bedifferent. The predetermined number of tail ends 71E and leading ends71T are input and set and stored in the control section 39.

In addition, at least the bottom side splice tape 76 is configured by anadhesive tape that contains metal. The splice tape detection sensor 33detects the bottom side splice tape 76 that contains metal. It ispossible to exemplify a sensor for a method for detecting capacitancebetween target objects as the splice tape detection sensor 33. Theexemplified splice tape detection sensor 33 determines that the spliceportion 79 is passing when the detected capacitance is large. The splicetape detection sensor 33 is one embodiment of the splice portiondetecting section of the present invention that is provided at adetection position further to the near side than the supply position 32.

Returning to FIG. 2, a communication connector 313 is provided at anapproximately intermediate height on the rear face of the main bodysection 31. The communication connector 313 communicates and connectsthe control section 39 and the control device 6 by fitting in acommunication connector on the pallet table 91 side. Furthermore, theoperation power of the feeder device 3 is supplied via the communicationconnector 313. Respective positioning pins 314 and 315 are provided atpositions on the top and the bottom to interpose the communicationconnector 313 on the rear face of the main body section 31. Thepositioning pins 314 and 315 fit in a positioning hole on the pallettable 91 side and determine an equipment position of the feeder device 3with respect to the pallet table 91.

A feeding sprocket 34 is supported on the lower side of the supplyposition 32 of the main body section 31. Teeth of the feeding sprocket34 protrude slightly upward from a hole that is bored in the tape guidemember 312 and fit into a sprocket hole 75 of the carrier tape 71. Thefeeding sprocket 34 feeds out the carrier tape 71 at a pitch feed whenintermittently driven to restate by a feeding motor 35.

Thereby, the carrier tape 71 is fed out to the supply position 32 fromthe tape reel 7 through the tape guide member 312. The cover tape 73 ispeeled off from the bottom tape 72 and folded back at the peelingposition 318 in front of the supply position 32 and is returned to thefront side. The bottom tape 72 that is opened by the cavity section 74supplies the component P to the suction nozzle 46 at the supply position32. The bottom tape 72 is discharged to the rear side of the feederdevice 3 after the component P is supplied.

A direction change roller 316 is disposed at a position further on thefront side than the tape guide member 312 on the upper portion of themain body section 31. Furthermore, a pair of discharge rollers 36 thatinterpose the cover tape 73 are provided at a position further on thelower side and front side than the direction change roller 316. The pairof discharge rollers 36 are supported on the main body section 31, andare driven to rotate by a discharge motor 37. The cover tape 73 thatreturns from the near side of the supply position 32 changes directionobliquely to the front and down by the direction change roller 316 andis discharged downward by a pair of discharge rollers 36.

The operation panel 38 is disposed further on the front side than thefront end of a handle 317 on the upper portion of the main body section31. FIG. 6 is a top view of an operation panel 38 of the feeder device3. The operation panel 38 has four push buttons 381 to 384, threeselector switches 385 to 387, and an abnormality display section 388.The feeding motor 35 is driven forward by pressing down the first pushbutton 381, and the carrier tape 71 is fed out. An error in the feedingamount of the carrier tape 71 is eliminated by performing originalignment of the rotational position of the feeding sprocket 34 bypressing down the second push button 382. In addition, the feeding motor35 is driven in reverse by pressing down the third push button 383, andthe carrier tape 71 is pulled back. The discharge motor 37 is driven bypressing down the fourth push button 384, and slack of the cover tape 73is wound.

The first selector switch 383 is a switch that switches between high andlow feeding speed of the carrier tape 71. The second selector switch 386is a switch that sets the type of the carrier tape 71 to either of anembossed tape or a paper tape. The third selector switch 387 is a switchthat selectively sets the feeding pitch of the carrier tape 71, that is,a disposition pitch of the cavity section 74 from out of 1 mm, 2 mm, and4 mm.

The abnormality display section 388 consists of three colors of LED(indicator lamp). A green LED 33 g, an orange LED 38 o, and a red LED 38r is able to take on a lit state, a flashing state, and an unlit statethat are independent of each other. The abnormality display section 388is able to be configured by unitized inexpensive general-purposeproducts. The detailed abnormality display function of the abnormalitydisplay section 388 will be described.

The control section 39 is disposed on the main body section 31 and theinstallation position is not particularly limited. The control section39 is a computer device that has a CPU and is operated by software, andcontrols operation of the feeder device 3. As shown in FIG. 3, thecontrol section 39 receives a detection signal of the splice tapedetection sensor 33 and exchanges information with the operation panel38. Furthermore, the control section 39 controls the operation of thefeeding motor 35 and the discharge motor 37. In addition, as describedabove, when the feeder device 3 is equipped on the pallet table 91, thecontrol section 33 communicates and connects with the control device 6.The control section 39 has a function of the passing determinationsection and the work defect determination section of the presentinvention.

In this arrangement, when the splicing work is defective, the spliceportion 79 that is indicated in FIGS. 4 and 5 is not formed correctly.In a defective splice portion 79, a tape feeding defect tends to occuras a result of peeling or catching of the splice tapes 76 and 77. Thefeeding defect tends to occur while discharging the cover side splicetape 77 using the discharge roller 36 after passing the splice tapedetection sensor 33 (detection position). That is, the cover side splicetape 77 may be caught in a neck position such as the peeling position318, the direction change roller 316, the discharge roller 36, and thelike.

Meanwhile, the feeding defect tends to occur while feeding out thebottom side splice tape 76 to the feeding sprocket 34 after passing thesplice tape detection sensor 33 until reaching the rear end of thefeeder device 3. Comparing the two splice tapes 76 and 77, the distanceat which the feeding defect tends to occur is longer than the cover sidesplice tape 77. Accordingly, it is possible to set the discharge roller36 that is the neck position furthest to the rear of the cover sidesplice tape 77 to the discharge position of the present invention.

According to this setting, the movement distance of the cover sidesplice tape 77 that reaches the discharge roller 36 (discharge position)is a predetermined length through the peeling position 318 and thedirection change roller 316 from the splice tape detection sensor 33(detection position). In addition, the interval from the splice tapedetection sensor 33 up to the discharge roller 36 is the passing area ofthe present invention. Information about a predetermined length andinformation about a separation distance between the splice tapedetection sensor 33 (detection position) and the supply position 32 isheld in advance in the control section 39.

(3. Operation of Component Mounting Machine 1 of Embodiment and FeederDevice 3 of First Embodiment)

Next, the operation of the component mounting machine 1 of theembodiment will be described. FIG. 7 is a diagram of a process flow thatexplains operation of the component mounting machine 1 of theembodiment. Note that, since the process flow is substantially advancedby the control section 39 of the feeder device 3, FIG. 7 is a diagramthat describes an operation of the feeder device 3 of the firstembodiment. In step S1 in FIG. 7, the control section 39 discriminateswhether or not the splice tape detection sensor 33 detects the spliceportion 79. When the splice portion 79 is detected, the control section39 advances the execution of the process flow to step S2. In addition,in step S3 when the splice portion 79 is not detected, the controlsection 39 discriminates whether or not the splice portion 79 is in thepassing state positioned in the passing area. When in the passing state,the control section 39 advances the execution of the process flow tostep S2.

In step S2, the control section 39 manages the position of the spliceportion 79. There are two specific sets of process content in step S2.In the first process content, the control section 39 manages the numberof remaining components that remain in the first carrier tape 71A. Inother words, the control section 39 manages a state in which the spliceportion 79 is fed out from the splice tape detection sensor 33 up to thesupply position 32. Thereby, the control section 39 is able to control(skip control) such that the splice portion, 79 and the cavity section74, which does not hold the components P in front and to the rear of thesplice portion 79, pass the supply position 32. Accordingly, when thereis no last component P of the first carrier tape 71A, insignificantsuction operations are omitted, and the first component P of the secondcarrier tape 71B is supplied to the supply position 32 in a short time.

In the second process content, the control section 39 determines whetheror not the splice portion 79 is in the passing state. That is, it isdetermined whether or not the splice portion 79 is fed out from thesplice tape detection sensor 33 by a predetermined length. The secondprocess content of step S2 and the process content of step S3 isequivalent to the passing determination section of the presentinvention.

When the splice portion 79 is not detected, and is not in the passingstate, the control section 39 advances the execution of the process flowto step S4 and performs the component supply operation. The componentsupply is an operation in a normal state in which the splice portion 79is not involved. In the subsequent step S5, the control section 39determines the suction abnormality state.

The suction abnormality state signifies that a suction mistake occurs inwhich the suction nozzle 46 is not able to suck the component P from thecavity section 74 of the supply position 32. The occurrence of thesuction mistake is able to be determined by imaging the suction nozzle46 from below by the component camera 5 or is able to be determined byimaging the suction nozzle 46 from the side by a camera device that isprovided on the mounting head 44. There are various variations in thedefinition of the suction abnormality state. For example, there may be asuction abnormality state with only one suction mistake, and there maybe the suction abnormality state when the suction mistake is noteliminated even if the suction operation is repeated a predeterminednumber of times with respect to the cavity section 74 at one location.Furthermore, in a case where the suction mistake is continued at thecavity section 74 at a predetermined number of locations, the suctionabnormality state is also possible. The suction abnormality state isdetermined by the component transfer device 4, and the determinationresult is transmitted from the control device 6 to the control section39. The process content of step S5 is equivalent to the suctionabnormality determination section of the present invention.

When the suction abnormality stats does not occur in step S5, thecontrol section 39 returns implementation of the process flow to stepS1, and transitions to the supply of the subsequent component P. Whenthe suction abnormality state occurs in step S5, the control section 39advances implementation of the process flow to step S6. In step S6, thecontrol section 39 commands general-purpose abnormality display(described in detail later) that represents the “suction abnormalitystate” to the operation panel 38, and stops thereafter.

After the position of the splice portion 79 is managed in step S2, thecontrol section 39 advances the execution of the process flow to stepS7, and performs component supply operation. The component supply is anoperation when the splice portion 79 is in the passing state. In thesubsequent step S8, the control section 39 determines the suctionabnormality state in the same manner as in step S5. The process contentof step S8 is equivalent to the suction abnormality determinationsection of the present invention.

When the suction abnormality state does not occur in step S8, thecontrol section 39 returns implementation of the process flow to stepS1, and transitions to the supply of the subsequent component P. Whenthe suction abnormality state occurs in step S8, the control section 39advances implementation of the process flow to step S9, and determinesthat the cause of the suction abnormality state is caused by thesplicing work defect. The process content of step S9 is equivalent tothe work defect determination section of the present invention. In thesubsequent step S10, the control section 39 commands dedicatedabnormality display (described in detail later) that represents the“suction abnormality state in the passing state of the splice portion79” to the operation panel 38, and stops thereafter.

Next, the display content of the abnormality display section 388 of theoperation panel 38 is described together with the related art. FIG. 8 isa table that indicates display content of the abnormality displaysection 388 of the operation panel 38. In FIG. 8, a column in whichhorizontal lines are filled in signifies non-use. The flashing state ofthe orange LED 38 o in the drawings is not used in the related art, andis display content that is added in the embodiment.

In the related art, the green LED 38 g of the abnormality displaysection 388 functions as a power display, and the orange LED 38 o is innon-use. In addition, the red LED 38 r functions as the abnormalitydisplay, and the operator is required to investigate and cope. Indetail, lighting of the green LED 38 g represents “power on”, and unlitrepresents “power off”. Lighting of the red LED 38 r represents “deviceabnormality” of the feeder device 3, flashing represents “suctionabnormality state”, and unlit represents “normal”. The “suctionabnormality state” is a state in which it is unknown whether or not thecause location is inside the feeder device 3, and therefore is displayeddifferently from the “device abnormality”.

Furthermore, in the embodiment, flashing of the orange LED 38 o is newlyused as a dedicated abnormality display. Plashing of the orange LED 38 orepresents the splice portion is in the passing state when the “suctionabnormality state” occurs that is represented by flashing of; the redLED 38 r. Accordingly, flashing of the orange LED 38 o is displayedtogether with the flashing of the red LED 38 r, and is not displayedalone.

Flashing of the red LED 38 r in the related art is performed as ageneral-purpose abnormality display that represents the “suctionabnormality state” in step S6 of the process flow in FIG. 7. Inaddition, flashing of the red LED 38 r and flashing of the orange LED 38o are performed together as a dedicated abnormality display thatrepresents the “suction abnormality state” in step S10.

(4. Modes and Effects of Component Mounting Machine 1 of Embodiment andFeeder Device 3 of First Embodiment)

The component mounting machine 1 of the embodiment is provided with: afeeder device 3 that feeds out the carrier tape 71 (71A, 71B) that isformed with cavity sections 74 that hold components P lined up in a rowand sequentially supplies the components P to the predetermined supplyposition 32; the component transfer device 4 that has the suction nozzle46 that sucks the component P from the cavity section 74 of the supplyposition 32 and mounts the Component P on a hoard K, the mounting head44 that holds the suction nozzle 46, and the head driving mechanisms(41-43) that drive the suction nozzle 46 and the mounting head 44; thesplice tape detection sensor 33 (splice portion detecting section) thatis provided at the detection position further on the near side than thesupply position 32 of the feeder device 3 and detects the splice portion79 that connects the tail end 71E of the first carrier tape 71A and theleading end 71T of the second carrier tape 71B with each other; thepassing determination section (step S2, step S3) that determines whetheror not the splice portion 79 is in the passing state in which theposition at which the splice portion 79 is fed out from the detectionposition by a longer predetermined length than the distance between thedetection position and the supply position 32 is referred to as adischarge position (discharge roller 36) and the splice portion 79 ispositioned within the passing area from the detection position to thedischarge position; the suction abnormality determination section (stepS5, step S8) that determines the suction abnormality state in which thesuction nozzle 46 is not able to suck the component P from the cavitysection 74 of the supply position 32; the work defect determinationsection (step S9) that determines the splicing work defect in a casewhere the suction abnormality state is determined and the splice portion79 is determined to be in the passing state; and the abnormality displaysection 388 that performs dedicated abnormality display in a case wherethe splicing work defect is determined.

Thereby, the splicing work defect is determined and dedicatedabnormality display is performed by flashing of an orange LED 38 o in acase where the suction abnormality state is determined in which it isnot possible for the suction nozzle 46 to suck the component P and thesplice portion 79 is determined to be in the passing state. Accordingly,when the suction abnormality state occurs, an operator is able todetermine whether or not the cause of the suction abnormality state iscaused by the splicing work defect by confirming whether or not theabnormality display section 388 performs dedicated abnormality display.

Furthermore, the abnormality display section 388 performsgeneral-purpose abnormality display by flashing of the red LED 38 r in acase where the suction abnormality state is determined and the spliceportion 79 is determined to not be in the passing state, and performsflashing (general-purpose abnormality display) of the red LED 38 rtogether with flashing (dedicated abnormality display) of the orange LED38 o in a case where the splicing work defect is determined.

Thereby, since the abnormality display section 388 requires only a minorchange from the conventional configuration, an increase in costs issuppressed. For example, the abnormality display function of theabnormality display section 388 that consists of three colors of LED(indicator lamps) that are described in the embodiment is able torealize only a device for control by firmware without adding hardware.

The feeder device 3 of the first embodiment is equipped in the componentmounting machine 1 and feeds out a carrier tape 71 (71A, 71B) that isformed with cavity sections 74 that hold components P lined up in a rowand sequentially supplies the components P to the predetermined supplyposition 32, the feeder device 3 provided with: the splice tapedetection sensor 33 (splice portion detecting section) that is providedat a detection position further on a near side than the supply position32 and detects the splice portion 79 that connects the tail end 71E ofthe first carrier tape 71A and the leading end 71T of the second carriertape 71B with each other; a passing determination section (step S2, stepS3) that determines whether or not the splice portion 79 is in thepassing state in which, when the position at which the splice portion 79is fed out from the detection position by a predetermined length longerthan a separation distance between the detection position, the supplyposition 32 is referred to as a discharge position (discharge roller 36)and the splice portion 79 is positioned within the passing area from thedetection position to the discharge position; a work defectdetermination section (step S9) that determines a splicing work defectin a case where the suction abnormality state is determined in which thecomponent mounting machine 1 is not able to suck the component P fromthe cavity section 74 at the supply position 32 and the splice portion79 is determined: to be in the passing state; and an abnormality displaysection 388 that performs dedicated abnormality display in a case wherethe splicing work defect is determined.

Thereby, since the feeder device 3 of the first embodiment is providedwith substantially the same configuration requirements as the componentmounting machine 1 of the embodiment, the same effects as the componentmounting machine 1 of the embodiment occur.

Note that, the component mounting machine 1 of the embodiment is alsoable to be carried out as a splicing work defect determination method byreplacing the functions of the component mounting machine 1 in animplementation step. That is, a function in which the splice portion 79is detected by the splice tape detection sensor 33 is replaced in thesplice portion detection step. In addition, the function of the passingdetermination section is replaced in a passing determination step, thefunction of the suction abnormality determination section is replaced inah suction abnormality determination step, and the function of the workdefect determination section is replaced in a work defect determinationstep. Furthermore, the function in which the abnormality display section388 performs dedicated abnormality display is replaced in theabnormality display step.

In the splicing work defect determination method of the embodiment thatconsists of each step described above, the same effects occur in thecomponent mounting machine 1 of the embodiment.

(5. Feeder Device of Second Embodiment)

Next, concerning the feeder device of the second embodiment, thedifferent functions and operations from the first embodiment are mainlydescribed. The feeder device of the second embodiment is the same as thefeeder device 3 of the first embodiment with regard to the hardwareconfiguration, and the function of the control section 39 and thedisplay content of the abnormality display section 388 are different.FIG. 9 is a diagram of a process flow of a control section 39 thatexplains operation of a feeder device of the second embodiment. In theprocess flow of the second embodiment, the process content of step S1 tostep S6 are the same as the first embodiment. In step S11 after step S2in FIG. 9, the control section 39 commands display of the splice portion79 in the passing state on the operation panel 38, and implementation ofthe subsequent process flow advances to step S4.

FIG. 10 is a table that indicates display content of the abnormalitydisplay section 388 in the second embodiment. As exemplified, instead ofthe flashing state of the orange LED 38 o in the first embodiment, inthe second embodiment, the lighting of the orange LED 38 o representsthe “passing state” of the splice portion 79, and turning off representsthe “normal state” in which the splice portion 79 is not involved.Unrelated to the abnormality display content of the red LED 38 r, theorange LED 38 o switches from being lit and unlit dependent on only theposition of the splice portion 79.

In the second embodiment, when the red LED 38 r is flashing, theoperator is able to determine whether or not the “suction abnormalitystate” is caused by the splicing work defect by referring to whether ornot the orange LED 38 o is lit. In addition, unrelated to the display ofthe red LED 38 r, the operator is able to ascertain whether or not thesplice portion 79 is in the passing state.

The feeder device of the second embodiment is equipped in the componentmounting machine 1 and feeds out the carrier tape 71 that is formed withcavity sections 74 that hold components P lined up) in a row andsequentially supplies the components P to a predetermined supplyposition 72, the feeder device provided with: a splice tape detectionsensor 33 (splice portion detecting section) that is provided at adetection position further on a near side than the supply position 72and detects the splice portion 79 that connects the tail end 71E of thefirst carrier tape 71A and the leading end 71T of the second carriertape 71B with each other; a passing determination section (step S2, stepS3) that determines whether or not the splice portion 79 is in a passingstate in which, when the position at which the splice portion 79 is fedout from the detection position by a predetermined length longer than aseparation distance between the detection position and the supplyposition 32 is referred to as a discharge position (discharge roller36), the splice portion 79 is positioned within the passing area fromthe detection position to the discharge position; and the orange LED 38o (passing display section) of the abnormality display section 388 thatdisplays that the splice portion 79 is in the passing state.

Thereby, when the suction abnormality state occurs in which the suctionnozzle 46 does not suck the component P, the operator is able todetermine whether or not the cause of the suction abnormality state iscaused by the splicing work defect by referring to whether or not theorange LED 38 o is lit.

(6. Applications and Modifications of Embodiment)

Note that, as the splice portion detecting section, instead of thesplice tape detection sensor 33, it is possible to use a tape imagingcamera. The tape imaging camera detects the splice tapes 76 and 77 byimage processing the acquired image data by imaging the carrier tape 71.In addition, in each embodiment, the abnormality display section 388 maybe provided in a location other than the feeder device 3, for example,the display section of the control device 6. The configuration of theabnormality display section 388 and the method of the abnormalitydisplay are able to be variously modified. Furthermore, the presentinvention is able to be implemented in the feeder device with astructure in which only one side of the two adhesive sections of thecover tape 73 is peeled and the cavity section 74 is open, and the covertape 73 and the bottom tape 72 are integrally discharged without anychanges. Various other applications and modifications of the presentinvention are possible.

REFERENCE SIGNS LIST

1: component mounting machine, 2: board conveyance device, 3: feederdevice, 31: main body section, 33: splice tape detection sensor, 34:feeding sprocket, 36: discharge roller, 38: operation panel, 388:abnormality display section, 38 g: green LED, 38 o: orange LED, 38 r:red LED, 39: control section, 4: component transfer device, 46: suctionnozzle, 5: component camera, 6: control device, 7: tape reel, 71, 71 a,71 b: carrier tape, 72: bottom tape, 73: cover tape, 74: cavity section,76: bottom side splice tape, 77: cover side splice tape, 79: spliceportion

The invention claimed is:
 1. A feeder device that is equipped in acomponent mounting machine, feeds out a carrier tape that is formed withcavity sections, that hold components, lined up in one row, andsequentially supplies the components to a predetermined supply position,the device comprising: a splice portion detecting sensor that isprovided at a detection position further on a near side than the supplyposition and detects the splice portion that connects a tail end of afirst carrier tape and a leading end of a second carrier tape with eachother; a controller configured to determine whether or not the spliceportion is in a passing state in which, the splice portion is positionedwithin a passing area from the detection position to a dischargeposition; and determine a suction abnormality state in which the suctionnozzle is not able to suck the component from the cavity section of thesupply position based on imaging the suction nozzle with an imagingdevice; and a display that displays a first display state when thesplice portion is in the passing state, and displays a second displaystate when the suction abnormality state is determined and the spliceportion is determined not to be in the passing state, the first displaystate being different from the second display state.
 2. A feeder devicethat is equipped in a component mounting machine, feeds out a carriertape that is formed with cavity sections, that hold components, lined upin one row, and sequentially supplies the components to a predeterminedsupply position, the device comprising: a splice portion detectingsensor that is provided at a detection position further on a near sidethan the supply position and detects the splice portion that connects atail end of a first carrier tape and a leading end of a second carriertape with each other; a controller configured to determine whether ornot the splice portion is in a passing state in which the splice portionis positioned within a passing area from the detection position to adischarge position; and determine a splicing work defect when a suctionabnormality state is determined in which the component mounting machineis not able to suck the component from the cavity section at the supplyposition based on imaging the suction nozzle with an imaging device, andthe splice portion is determined to be in the passing state; and anabnormality display that displays a first display state when thesplicing work defect is determined, and displays a second display statewhen the suction abnormality state is determined and the splice portionis determined not to be in the passing state, the first display statebeing different from the second display state.
 3. A component mountingmachine comprising: a feeder device that feeds out a carrier tape thatis formed with cavity sections, that hold components, lined up in onerow and sequentially supplies the components to a predetermined supplyposition; a component transfer device including a suction nozzle thatsucks the component from the cavity section of the supply position andmounts the component on a board, a mounting head that holds the suctionnozzle, and head driving mechanisms that drive the suction nozzle andthe mounting head; a splice portion detecting sensor that is provided ata detection position further on a near side than the supply position ofthe feeder device and detects the splice portion that connects a tailend of a first carrier tape and a leading end of a second carrier tapewith each other; a controller configured to determine whether or not thesplice portion is in a passing state in which the splice portion ispositioned within a passing area from the detection position to adischarge position; determine a suction abnormality state in which thesuction nozzle is not able to suck the component from the cavity sectionof the supply position based on imaging the suction nozzle with animaging device; and determine a splicing work defect when the suctionabnormality state is determined and the splice portion is determined tobe in the passing state; and an abnormality display that displays afirst display state when the splicing work defect is determined, anddisplays a second display state when the suction abnormality state isdetermined and the splice portion is determined not to be in the passingstate, the first display state being different from the second displaystate.
 4. A splicing work defect determination method for determining adefect of splicing work in which a tail end of a first carrier tape anda leading end of a second carrier tape are connected with each other, ina component mounting machine provided with a feeder device that feedsout a carrier tape that is formed with cavity sections that holdcomponents lined up in one row and sequentially supplies the componentsto a predetermined supply position, and a component transfer device thathas a suction nozzle that sucks the component from the cavity section ofthe supply position and mounts the component on a board, a mounting headthat holds the suction nozzle, and head driving mechanisms that drivethe suction nozzle and the mounting head, the method comprising:detecting the splice portion at a detection position ftirther on a nearside than the supply position of the feeder device; determining whetheror not the splice portion is in a passing state in which the spliceportion is positioned within a passing area from the detection positionto a discharge position; determining a suction abnormality state inwhich the suction nozzle is not able to suck the component from thecavity section of the supply position based on imaging the suctionnozzle with an imaging device; determining a splicing work defect whenthe suction abnormality state is determined and the splice portion isdetermined to be in the passing state; displaying a first display statewhen the splicing work defect is determined; and displaying a seconddisplay state when the suction abnormality state is determined and thesplice portion is determined not to be in the passing state, the seconddisplay state being different from the first display state.